Polymer Particle Transfer Between Series Zones Using Parallel Vessels

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Solution Overview

Problem

Existing processes for transferring polymer particles between polymerization zones in series are energy-inefficient, lead to carry-over of reactive gases, and risk contamination between zones, complicating the system and reducing product quality.

Innovation Solution

A process and system that involves separating the product from a first polymerization zone into a gas and solid phase, using transfer vessels in parallel communication to reduce reactive gas carry-over, and employing alternating pressure equalization to minimize energy consumption and contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If polymer particles are transferred between polymerization zones using existing processes, then polymer particles can be transferred from one zone to another, but energy consumption increases and reactive gases are carried over between zones

Engineering Contradiction:

Improveenergy consumptionVSAvoidpolymer particle transfer efficiency

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

The transfer system is segmented into multiple independent transfer vessels (first transfer vessel and second transfer vessel) that operate in parallel. This segmentation allows the system to perform pressure equalization in one vessel while the other handles particle transfer, reducing overall energy consumption by avoiding simultaneous pressurization of all vessels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system employs periodic alternating operation between the first and second transfer vessels. While one vessel is being used for particle transfer, the other undergoes pressure equalization. This periodic switching reduces energy consumption by ensuring that not all vessels require full pressurization at the same time, while maintaining continuous particle transfer capability.

Inventive Principle:

Principle #19Periodic action

2Productivity

If polymer particles are transferred between polymerization zones, then product can move from first zone to second zone, but contamination between zones occurs

Engineering Contradiction:

Improvepolymer particle transfer capabilityVSAvoidcontamination between polymerization zones

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The transfer vessels serve as intermediary chambers between the first and second polymerization zones. Polymer particles are transferred from the first zone to the transfer vessels, then to the second zone, preventing direct contact and contamination between the polymerization zones. The intermediary vessels can be isolated and pressurized independently, maintaining zone separation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If transfer vessels are used to move polymer particles, then particle transfer is achieved, but system complexity increases

Engineering Contradiction:

Improvepolymer particle transfer functionVSAvoidnumber of transfer vessels and communication pathways

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Each transfer vessel is designed with multi-functionality: they can handle particle transfer from the first polymerization zone, perform pressure equalization with the second polymerization zone, and serve as isolation chambers. This universal design reduces the need for additional specialized equipment, managing system complexity while maintaining transfer functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Reduces energy consumption and prevents contamination between polymerization zones, improving product quality by effectively transferring polymer particles while maintaining flexible operation.

Implementation Method 1

employing alternating pressure equalization to minimize energy consumption and contamination

Methodology Applied

Scientific EffectPressure equalization: Pressure Gradient

Implementation Method 2

separating the product from a first polymerization zone into a gas and solid phase

Methodology Applied

Scientific EffectGas-solid separation: Cyclone Separation

Data Source

PatentEP4631613A1Process and system for transferring polymer particles between polymerization zones arranged in series

Publication Date: 2025.10.15 LUMMUS NOVOLEN TECH

Figure 1

AI summary

A process is provided for transferring a product from a first polymerization zone (101) to a second polymerization zone (301) arranged in series with the first polymerization zone (101). The process comprises: discharging a product of the first polymerization zone (101) from the first polymerization zone (101); separating the product into a gas phase comprising any unreacted monomer and gaseous agent used in the first polymerization zone (101), and a solid phase comprising a polymerization product; and transferring the solid phase to the second polymerization zone (301) via at least one of a first transfer vessel (202) and a second transfer vessel (203) arranged in parallel to each other and in selective communication with each other, wherein the at least one of the first transfer vessel (202) and second transfer vessel (203) is further in selective communication with the second polymerization zone (301), and the second polymerization zone (301) is a gas-phase polymerization zone.